Steel core brass stair rod

ABSTRACT

A method of making a steel core brass stair rod includes placing a brass billet into a chamber of an extrusion apparatus, where the brass billet includes an aperture configured to receive a steel core. The brass billet is heated to a temperature at which the brass billet is pliable. The brass billet and the steel core are co-extruded through a die of the extrusion apparatus such that the brass billet forms a brass shell which is fused to the steel core, where there is no air gap between the brass shell and the steel core.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a Divisional of U.S. patent application Ser. No.11/696,409, filed Apr. 4, 2007, the entire disclosure of which isincorporated herein by reference.

FIELD

The subject of the disclosure relates generally to stair rods. Morespecifically, the disclosure relates to a stair rod which includes asolid brass outer shell fused to a steel core such that there are no airspaces between the solid brass outer shell and the steel core.

BACKGROUND

A stair rod can be a support member used to secure a carpet, a rug, orother material to a stair (or step). There are currently six types ofstair rods in use: solid brass stair rods, brass tube stair rods, solidsteel stair rods, steel tube stair rods, aluminum stair rods, and woodstair rods. A solid brass stair rod is desirable because it provides theaesthetically pleasing look of real brass, because it is of sufficientweight, and because it generates an acceptable sound when it is kickedor otherwise touched as an individual goes up and down a set of stairs.However, due to its composition, the solid brass stair rod isprohibitively expensive when compared to the other types of stair rods.As a result, a set of solid brass stair rods is often more expensivethan the stair carpet runner which the stair rods are meant to adorn. Inaddition, the solid brass stair rod is also extremely flexible and proneto bending, especially as the length of the brass stair rod increases.This flexibility can be problematic during installation and can resultin a safety hazard when the solid brass stair rod is in use.

As with the solid brass stair rod, the brass tube stair rod is also madeof 100% brass. However, because of its hollow center, the brass tubestair rod generally requires about 50% less brass than a solid brassstair rod of the same diameter. As a result, the brass tube stair rod ismore affordable than the solid brass stair rod, while still providingthe aesthetically pleasing look of real brass. However, the brass tubestair rod lacks an aesthetically desirable weight and produces a cheap‘tin-like’ sound when it is touched or kicked by passersby. The brasstube stair rod is also extremely flexible and even more likely to bendthan the solid brass stair rod. Also, brass tube stair rods with thinwalls are susceptible to being dented, twisted, punctured, or otherwisedeformed while in use.

The solid steel stair rod provides a high level of strength which isgenerally not prone to bending or deformity, even in longer lengths.Similar to the solid brass stair rod, the solid steel stair rod alsosatisfies the aesthetically desirable attributes of weight and soundwhen in use. In addition, steel is much less expensive than brass.However, the solid steel stair rod has a very poor appearance which isaesthetically unacceptable to most individuals. Further, the solid steelstair rod is susceptible to rusting if left untreated. In an attempt toimprove the appearance of the solid steel stair rod and prevent itsrusting, the solid steel stair rod can be plated with a brass coating.However, brass plating does not produce the same appearance as solidbrass, and as a result, a brass plated stair rod can easily be visuallydistinguished from a solid brass stair rod by its light appearance, lackof richness, and poor depth of color. As such, a brass plated stair rodis not as aesthetically desirable in appearance as the solid brass stairrod. The brass plating is also susceptible to bubbling, flaking, and/orother inconsistencies. These problems can be caused by imperfections onthe steel surface, imperfections within the brass plating material, animproperly implemented plating process, etc. In addition, brass platingis a complicated process which creates a considerable amount of wastewater and vapor, both of which are harmful to the environment.

The steel tube stair rod provides a much lower cost than the solid brassstair rod, the brass tube stair rod, or the solid steel stair rod.However, the steel tube is not desirable in appearance, does not have adesirable weight, and does not produce a desirable sound. Further, brassplating the steel tube stair rod does not produce a desirable stair rodfor the same reasons described above with reference to the solid steelstair rod.

The aluminum stair rod, which is generally low in price, is the leastcommon type of stair rod. The aluminum stair rod does not have theaesthetically desirable appearance of brass. To remedy its appearance,the aluminum stair rod can be colored (not plated) to a gold-like colorusing a method called anodizing. While the color produced throughanodizing is similar to brass, it is not close enough for mostconsumers. In addition, the aluminum stair rod is poor in terms ofweight, the sound which it produces, and its strength when in use.Overall, the aluminum stair rod is generally deemed the least desirabletype of stair rod.

As with the aluminum stair rod, the wood stair rod is another uncommonlyused type of stair rod. Wood stair rods are inexpensive and produce anacceptable sound when kicked or otherwise contacted. However, the woodstair rod bends easily and is susceptible to breaking. Also, theappearance of wood is not aesthetically pleasing to most consumers.

Thus, there is a need for a stair rod which is affordable, whichproduces a desirable (non-tinny) sound when struck, which has theaesthetically desirable appearance of real brass, which has a desirableweight, which is not flexible or otherwise susceptible to deformation,and which is not environmentally harmful.

SUMMARY

An exemplary steel core brass stair rod includes a steel core with anexterior surface. A brass shell is fused to the exterior surface of thesteel core through a heating process such that there is not an air gapbetween the brass shell and the exterior surface of the steel core.

An exemplary method of making a steel core brass stair rod includesplacing a brass billet into a chamber of an extrusion apparatus. Thebrass billet has an aperture capable of receiving a steel core. Thebrass billet is heated to a temperature at which the brass billet ispliable. The brass billet and the steel core are co-extruded through adie of the extrusion apparatus such that the brass billet forms a brassshell which is fused to the steel core, wherein there is no air gapbetween the brass shell and the steel core.

Another exemplary method of making a steel core brass stair rod includesplacing a brass tube into a chamber of a drawing apparatus, wherein thebrass tube is capable of receiving a steel core. The method alsoincludes heating the brass tube to a temperature at which the brass tubeis pliable. The method further includes co-drawing the brass tube andthe steel core through a die of the drawing apparatus such that thebrass tube forms a brass shell which is fused to the steel core, whereinthere is no air gap between the brass shell and the steel core.

Other principal features and advantages will become apparent to thoseskilled in the art upon review of the following drawings, the detaileddescription, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments will hereafter be described with reference to theaccompanying drawings.

FIG. 1 is a flow diagram illustrating operations performed to create asteel core brass stair rod in accordance with an exemplary embodiment.

FIG. 2 is a cross-sectional side view of an extrusion apparatus inaccordance with an exemplary embodiment.

FIG. 3 is a front view of the extrusion apparatus of FIG. 2 inaccordance with an exemplary embodiment.

FIG. 4 is a cross-sectional side view of a drawing apparatus inaccordance with an exemplary embodiment.

FIG. 5 is a partial perspective view of a steel core brass stair rod inaccordance with an exemplary embodiment.

DETAILED DESCRIPTION

FIG. 1 is a flow diagram illustrating operations performed to create asteel core brass stair rod in accordance with an exemplary embodiment.Additional, fewer, or different operations may be performed inalternative embodiments. In an operation 100, a piece of brass is placedin a chamber of a heating apparatus. In an exemplary embodiment, thepiece of brass can be a brass billet. Alternatively, the piece of brasscan be a brass tube, a brass ring, or any other brass base. In anoperation 105, a steel core is placed in the chamber of the heatingapparatus. The steel core can be made of any type of steel known tothose of skill in the art. In an exemplary embodiment, the steel corecan be solid steel and can have a cylindrical shape. Alternatively, thesteel core can be any other shape, including rectangular, triangular,etc. In another alternative embodiment, the steel core can be a steeltube with a hollow center. In an alternative embodiment, steel may notbe used, and the core may be made of any other metallic material whichhas a significantly higher melting point than brass.

In an exemplary embodiment, the piece of brass can include an aperturecapable of receiving the steel core. The aperture can be located at acenter of the piece of brass, or off-center, depending on theembodiment. In one embodiment, the aperture can be the same shape as thesteel core. Alternatively, the aperture can be any other shape capableof receiving the steel core. In another exemplary embodiment, the pieceof brass can be the same shape as the chamber into which it is placed.

In an exemplary embodiment, the heating apparatus can be an extrusionapparatus. FIG. 2 is a cross-sectional side view of an extrusionapparatus 200 in accordance with an exemplary embodiment. Extrusionapparatus 200 includes a chamber 205, a die holder 210, a die 215, apressure plate 220, a ram 225, and a casing 230. A brass billet 235 canbe placed within chamber 205. A steel core 240 can also be placed withinchamber 205 and through an aperture of brass billet 235. In an exemplaryembodiment, pressure plate 220 and/or ram 225 can also include aperturescapable of receiving steel core 240.

Referring back to FIG. 1, the chamber is heated to a temperature atwhich the piece of brass is pliable in an operation 110. The chamber canbe heated by any method known to those of skill in the art. In anexemplary embodiment, the temperature can be a melting point temperatureof brass, which is approximately 1700° Fahrenheit (F). Alternatively,the temperature can be greater than the melting point temperature ofbrass. In another alternative embodiment, the temperature can be lessthan the melting point temperature of brass, but still hot enough suchthat the piece of brass is pliable. In another exemplary embodiment, thetemperature can be less than a melting point temperature of steel, whichis approximately 2500°-2700° F. As such, there can be no risk of thesteel core melting or otherwise deforming during the creation of thesteel core brass stair rod.

In an operation 115, the heated piece of brass and the steel rod areforced through a die of the heating apparatus such that a brass shell isfused to an exterior surface of the steel core. In an exemplaryembodiment, the steel core can be manually pushed through extrusionapparatus. Alternatively, the steel core may be automatically drawnthrough the heating apparatus. In another exemplary embodiment, becausethe piece of brass is pliable, it can conform to the steel core suchthat there is no air space between the brass shell and the steel core.For example, the exterior surface of the steel core may have ridges,valleys, burrs, and/or other imperfections. An interior of the brassshell can precisely conform to any of these imperfections such that thebrass shell and the steel core essentially become a single piece ofmetal. As such, there is no risk that the steel core can rattle, click,or otherwise move around and make noise within the brass shell. Anexterior of the brass shell can be perfectly smooth and visuallyappealing because the exterior of the brass shell is formed by the dieand is not dependent on the flawed exterior surface of the steel core.Further, the brass shell can be any desired thickness. In an exemplaryembodiment, different dies and/or methods of manufacturing can be usedto produce brass shells of different thicknesses.

Referring back to FIG. 2, chamber 205 can be heated to a temperaturesuch that brass billet 235 is pliable. Once brass billet 235 is pliable,extrusion apparatus 200 can be used to co-extrude brass billet 235 andsteel core 240 through die 215. In an exemplary embodiment, pressureplate 220 can make a tight seal with an interior wall of chamber 205such that brass billet 235 is not able to leak behind pressure plate 220as pressure plate 220 is pushed along chamber 205. Ram 225 can used topush pressure plate 220 along chamber 205 such that pressure plate 220forces brass billet 235 and steel core 240 through die 215. Ram 225 canbe mounted to pressure plate 220, or detachable therefrom, depending onthe embodiment. Pressure can be manually applied to ram 225 by anindividual, automatically applied to ram 225 by a computer activatedmechanism, hydraulically applied to ram 225, or applied to ram 225 byany other method known to those of skill in the art.

In an exemplary embodiment, steel core 240 and brass billet 235 can passthrough die 215 at the same rate. Alternatively, steel core 240 andbrass billet 235 can pass through die 215 at differing rates. Die 215can include a die aperture capable of shaping an exterior surface of abrass shell 245 as brass shell 245 is simultaneously formed and fused tosteel core 240. In an exemplary embodiment, the die aperture can becircular. Alternatively, the die aperture can be any other shape. FIG. 3is a front view of extrusion apparatus 200 of FIG. 2 in accordance withan exemplary embodiment. FIG. 3 illustrates die holder 210, die 215, andco-extruded brass shell 245 fused to steel core 240.

In an exemplary embodiment, brass shell 245 can conform to steel core240 such that there is no air space between brass shell 245 and steelcore 240. The co-extruded brass shell 245 and steel core 240 can be cutto any desired length to form the steel core brass stair rod. Theco-extruded brass shell 245 and steel core 240 can be cut by any methodknown to those of skill in the art, and can be cut prior to orsubsequent to cooling, depending on the embodiment. In an exemplaryembodiment, the ends of the steel core brass stair rod can be covered byfasteners when the steel core brass stair rod is installed such thatthere is no visible steel in the installed product. Alternatively, brasscan be fused to the ends of the steel core brass stair rod such thatthere is no visible steel in the finished product.

In an alternative embodiment, the heating apparatus described withreference to FIG. 1 can be a drawing apparatus. The drawing apparatuscan be used to form a brass shell which is thinner than brass shell 245formed by extrusion apparatus 200 described with reference to FIGS. 2and 3. FIG. 4 is a cross-sectional side view of a drawing apparatus 400in accordance with an exemplary embodiment. Drawing apparatus 400includes a chamber 405, a die holder 410, a die 415, a pressure plate420, a ram 425, and a casing 430. Pressure plate 420 and/or ram 425 canhave apertures capable of receiving a steel core 440.

In an exemplary embodiment a brass tube 435 and steel core 440 can beplaced in drawing apparatus 400. Brass tube 435 can have a significantlysmaller diameter than brass billet 235 described with reference to FIG.2. Brass tube 435 can also have an aperture capable of receiving steelcore 440. Chamber 405 can be heated such that brass tube 435 is madepliable. In an exemplary embodiment, the drawing process can be similarto the extrusion process described with reference to FIGS. 2 and 3. Ram425 can apply pressure to pressure plate 420 such that brass tube 435and steel core 440 can be co-drawn through die 415. A brass shell 445can be fused to steel core 440 such that there is no air space betweenbrass shell 445 and steel core 440. The co-drawn brass shell 445 andsteel core 240 can be cut to any desired length to form the steel corebrass stair rod. In an alternative embodiment, the steel core brassstair rod can be made by any other method capable of fusing a brassshell to a steel core in an airtight fashion.

FIG. 5 is a partial perspective view of a steel core brass stair rod 500in accordance with an exemplary embodiment. Steel core brass stair rod500 includes a brass shell 505 fused to a steel core 510. In anexemplary embodiment, steel core brass stair rod 500 can be made usingan extrusion process, a drawing process, or any other process capable offusing brass shell 505 to steel core 510 such that there are no airspaces between brass shell 505 and steel core 510.

The steel core brass stair rod described herein overcomes thelimitations of the above-described prior art stair rods. The steel corebrass stair rod can be inexpensive because it can be made by using asmall amount of brass. The steel core brass stair rod can have adesirable weight because it can be made solid throughout its diameter(or width). Because the brass shell is fused to the brass core in anairtight manner, the steel core brass stair rod does not produceundesirable ‘tinny’ or other sounds as individuals go up and down a setof stairs. In addition, because of the steel core, there is no risk thatthe steel core brass stair rod will bend or otherwise deform during useor installation. The steel core brass stair rod also has anaesthetically desirable appearance because the solid brass shell is theonly visible metal when the steel core brass stair rod is installed.Unlike brass plating, the brass shell is genuine brass and does notsuffer from a light appearance or other discoloration. In addition, theco-extrusion and co-drawing methods described herein are significantlymore friendly to the environment than the brass plating method used inthe prior art.

It is also important to understand that the steel core brass stair roddescribed herein is significantly different from a brass tube with asteel core insert. A brass tube with an non-fused steel core insertwould suffer from the same limitations as described with reference tothe prior art. As known to those of skill in the art, brass tubes aremanufactured with a specified tolerance. For example, a brass tube witha wall thickness of 0.031 inches might require a tolerance of ±0.0005inches along the entire length of the brass tube. This alone allows avariation of up to 0.001 inches in the wall thickness along the brasstube. If a steel core is inserted into such a brass tube, the variationcan result in undesirable air spaces between the steel core and thebrass tube. The undesirable air spaces can allow the steel core to movewithin the brass tube such that undesirable noises are generated. Inaddition, the interior surface of a brass tube is left rough, and thereis no commercially available process of polishing it smooth. This roughinterior surface would also contribute to undesirable air spaces betweenthe brass tube and a steel core insert.

Use of a non-fused steel core insert would further be limited because anexterior surface of a steel core (or rod) is generally extremely roughafter it is manufactured. Leaving this rough exterior surface wouldresult in many air spaces between the steel core and the brass tube.Polishing the exterior surface of the steel core to make it smooth wouldalso cause air spaces because the act of polishing removes steel fromthe steel core, resulting in a smaller diameter steel core which is freeto move about within the brass tube. Further, current manufacturingmethods of both brass tubes and steel cores (rods) have tolerances withrespect to curvature. A brass tube and/or steel core which is curved cancause significant air spaces between the brass tube and steel core.Thus, it can be seen that simply inserting a non-fused steel core into abrass tube would not solve the above-described limitations oftraditional stair rods.

One or more flow diagrams have been used to describe exemplaryembodiments. The use of flow diagrams is not meant to be limiting withrespect to the order of operations performed. The foregoing descriptionof exemplary embodiments has been presented for purposes of illustrationand of description. It is not intended to be exhaustive or limiting withrespect to the precise form disclosed, and modifications and variationsare possible in light of the above teachings or may be acquired frompractice of the disclosed embodiments. It is intended that the scope ofthe invention be defined by the claims appended hereto and theirequivalents.

1. A method of making a steel core brass stair rod comprising: placing abrass billet into a chamber of an extrusion apparatus, wherein the brassbillet comprises an aperture configured to receive a steel core; heatingthe brass billet to a temperature at which the brass billet is pliable;and co-extruding the brass billet and the steel core through a die ofthe extrusion apparatus such that the brass billet forms a brass shellwhich is fused to the steel core, wherein there is no air gap betweenthe brass shell and the steel core.
 2. The method of claim 1, whereinthe temperature is greater than or equal to a melting point temperatureof the brass billet.
 3. The method of claim 1, wherein the temperatureis less than a melting point temperature of the steel core.
 4. Themethod of claim 1, wherein co-extruding the brass billet and the steelcore comprises applying a force to a ram of the extrusion apparatus suchthat the ram causes a pressure plate of the extrusion apparatus to forcethe brass billet and the steel core through the die.
 5. The method ofclaim 4, wherein the pressure plate comprises an aperture configured toreceive the steel core.
 6. The method of claim 4, wherein the ramcomprises an aperture configured to receive the steel core.
 7. Themethod of claim 1, wherein the die comprises a circular aperture of aspecified diameter.
 8. A method of making a steel core brass stair rodcomprising: placing a brass tube into a chamber of a drawing apparatus,wherein the brass tube is configured to receive a steel core; heatingthe brass tube to a temperature at which the brass tube is pliable; andco-drawing the brass tube and the steel core through a die of thedrawing apparatus such that the brass tube forms a brass shell which isfused to the steel core, wherein there is no air gap between the brassshell and the steel core.
 9. The method of claim 8, wherein the drawingapparatus further comprises: a pressure plate which forms a seal with aninterior of the chamber; and a ram configured to apply a force to thepressure plate such that the pressure plate forces the brass tube andthe steel core through the die.
 10. The method of claim 9, wherein theram and the pressure plate comprise apertures configured to receive thesteel core.
 11. The method of claim 8, wherein the brass tube and thesteel core are drawn through the die at an identical rate.